CN110436926A - 一种高电导率受电弓碳滑板及其制备方法 - Google Patents

一种高电导率受电弓碳滑板及其制备方法 Download PDF

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CN110436926A
CN110436926A CN201910793530.9A CN201910793530A CN110436926A CN 110436926 A CN110436926 A CN 110436926A CN 201910793530 A CN201910793530 A CN 201910793530A CN 110436926 A CN110436926 A CN 110436926A
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carbon
pantograph
preparation
high conductivity
pantograph carbon
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CN110436926B (zh
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魏文赋
廖前华
吴广宁
杨泽锋
左浩梓
高国强
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Southwest Jiaotong University
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Abstract

本发明公开了一种高电导率受电弓碳滑板及其制备方法，在碳滑板制备过程的混粉阶段添加造孔剂，得到具有连通孔隙的碳滑板，从而提高碳滑板的导电率；采用钎料与铜金属熔融混合浸渍受电弓碳滑板，使得铜‑钎料‑碳三种材料紧密结合在一起，从而增强铜‑碳界面结合力；在浸渍过程中外加强磁场作用，驱动铜合金液在受电弓滑板坯体孔隙内均匀扩散，提高浸渍效率，进而增强碳滑板的机械强度和耐电弧烧蚀能力。本发明利用添加造孔剂、钎焊、外加强磁场作用的方法可有效解决受电弓碳滑板导电率不高、机械强度不够、耐电弧烧蚀性能差等问题，为制备具有高性能的受电弓碳滑板提供了新思路。

Description

一种高电导率受电弓碳滑板及其制备方法
技术领域
本发明属于电弧电接触设备技术领域，具体涉及一种高电导率受电弓碳滑板及其制备方法。
背景技术
电碳材料是以碳和石墨为基体的一种具有特殊功能的电工材料，用于制造电工设备的固定电接触或转动电接触的零部件等，例如，用于电机的电刷，电力开关和继电器的石墨触头以及受电弓等；此外，还用于弧光放电的石墨电极，光谱分析用的碳棒，碳膜及碳电阻，碳和石墨电热元件，干电池碳棒，大型电子管石墨阳极和栅极等。受实用场合的限制，电碳材料一般需要具有优良的导电率。
受电弓与接触网系统是列车能量供给的重要途径。为了保护接触网铜导线，在列车受电弓上普遍采用润滑性较好的碳滑板作为集电元件。为了进一步提高碳滑板的导电率，目前一般采用铜金属液浸渍碳滑板的方法。但是，因为现有受电弓碳滑板内部孔隙不连通、碳相与铜相互不湿润、铜金属液很难在碳滑板坯体孔隙内均匀扩散，导致目前铜金属液浸渍碳滑板的浸渍效率非常低，浸渍后碳滑板的导电率仍然不高、机械强度不强、耐电弧烧蚀性能也不好。
发明内容
针对上述现有技术，本发明提供一种高电导率受电弓碳滑板及其制备方法，以解决受电弓碳滑板导电率不高、机械强度不强，耐电弧烧蚀性能不好的问题。
为了达到上述目的，本发明所采用的技术方案是：提供一种高电导率受电弓碳滑板及其制备方法，制备方法包括以下步骤：
(1)制备坯体：将包含造孔剂的碳滑板骨料预压为碳基柱体，然后将碳基柱体升温至70～85℃，保温10～20h，再升温至100～150℃，保温100～250h，然后复压得受电弓碳滑板坯体；所述造孔剂为直径为0.1～0.3mm、长度为50～100mm的线型材料；
(2)浸渍：将受电弓碳滑板坯体放入焙烧炉中，抽真空后加热至800～1300℃，同时加热铜合金和钎料至熔融状态，然后将熔融态的铜合金液倒入焙烧炉中浸没受电弓碳滑板坯体，接着充入保护气体至焙烧炉内压力为3～8MPa，同时外加3～14T的磁场，保持1～2h，完成浸渍；铜合金液中钎料的质量分数为1％～10％；
(3)烧结：在隔绝空气的条件下，用1000～1200℃的温度对浸渍后的碳滑板坯体进行烧结，烧结时间为15～20h，得碳滑板半成品；
(4)石墨化处理：将碳滑板半成品置于石墨化炉内，并加热至2300～2500℃，保温2～4h，得高电导率受电弓碳滑板。
在上述技术方案的基础上，本发明还可以做如下改进。
进一步，造孔剂占碳滑板骨料总重量的1～15％。
进一步，造孔剂占碳滑板骨料总重量的5％。
进一步，碳滑板骨料的制备方法为：取以下质量份的组分：沥青焦粉60～70份，石墨粉20～30份，高温沥青5～10份以及上述三种原料总质量1～15％的造孔剂；然后将沥青焦粉、石墨粉和造孔剂均匀混合，再加入熔融的高温沥青，于160～200℃下混合2～4h，然后冷却至室温并将混合料磨成200～300目的粉末，得碳滑板骨料。
进一步，造孔剂为甲基纤维素或碳酸铵。
进一步，步骤(2)中抽真空后的焙烧炉的真空度为0.05～0.2Pa。
进一步，钎料为同时与铜、碳材料相互结合很好的材料，如铁、钛、锆、铬等；钎料在铜合金液中的质量分数为5～8％。
进一步，保护气体为氮气或氩气。
进一步，浸渍过程中焙烧炉内压力为5MPa，外加磁场强度为8T。
进一步，焙烧炉外加的磁场包括但不限于由线圈绕组生成，磁场强度由线圈电流大小控制，磁场方向由不同线圈绕组分别工作产生。
进一步，步骤(4)中加热分两段进行，在碳滑板半成品温度达到1200℃以前，升温速率为5℃/min，超过1200℃以后，升温速率为30℃/h。
本发明的有益效果是：
1.在受电弓碳滑板制备过程的混粉阶段添加线型造孔剂，使得受电弓碳滑板内部孔隙连通，后续浸渍过程中铜金属浸渍液在碳滑板内部分布更加均匀，可显著提高碳滑板的导电率。
2.采用少量钎料(铁、钛等)与铜金属熔融混合，利用该铜合金液浸渍具有连通孔隙的受电弓碳滑板坯体，使得浸渍过程中铜-钎料-碳三种材料紧密结合在一起，增强铜-碳界面结合力，提升浸渍效果。
3.在浸渍过程中外加强磁场，可以抑制合金的液液分离以及导电熔体的对流作用，使得富铜相的分布更为均匀，同时合金晶内的溶质元素分布趋于均匀化，凝固组织中纤维间距减小，从而提高浸金属碳滑板的机械强度、导电能力和耐电弧烧蚀能力，延长滑板使用寿命。
附图说明
图1为铜-钎料混合液浸渍受电弓碳滑板坯体过程中炉墙抽真空示意图；
图2为铜-钎料混合液浸渍受电弓碳滑板坯体过程示意图；
图3为铜-钎料-碳相互结合示意图；
图4为外加磁场焙烧炉原理图；
其中，1、焙烧炉；2、机械臂；3、石墨坩埚；4、铜-钎料熔融金属；5、旋杆；6、受电弓碳滑板坯体；7、热电偶；8、出气口；9、烧结棒；10、导电线圈；11、冷却水系统。
具体实施方式
下面对本发明的具体实施方式进行描述，以便于本技术领域的技术人员理解本发明，但应该清楚，本发明不限于具体实施方式的范围，对本技术领域的普通技术人员来讲，只要各种变化在所附的权利要求限定和确定的本发明的精神和范围内，这些变化是显而易见的，一切利用本发明构思的发明创造均在保护之列。
本发明为了解决现有受电弓碳滑板导电率低的问题，提供了一种高电导率受电弓碳滑板的制备方法，该方法是在混粉阶段添加造孔剂，并采用少量钎料与铜金属熔融混合后的金属液浸渍受电弓碳滑板坯体，同时在浸渍过程中外加强磁场，以在碳滑板内部形成相互连通的孔隙，并增强碳相与铜相的浸润性以及铜金属液在碳滑板坯体孔隙内的均匀性。高电导率受电弓碳滑板的具体制备方法为：
1.混捏：取60～70质量份的沥青焦粉、20～30质量份的石墨粉和5～10质量份的高温沥青作为基料；按照重量配比将粒径为100目的沥青焦粉和粒径为200目的石墨粉放入混捏锅中，并添加占基料总质量1～15％的造孔剂，充分混合1h，所用造孔剂为易分解为气体的线型材料，如甲基纤维素(气化温度80℃左右)、碳酸铵(气化温度70℃左右)等，造孔剂的直径为0.1～0.3mm、长度为50～100mm；再加入熔融的高温沥青，在160～200℃的温度条件下混合2～4h，冷却后再将混料放入球磨机中进行磨粉处理，得到粒度为200～300目的碳滑板骨料。
2.压制：将碳滑板骨料在200T的液压机中预压为25mm*35mm*1200mm的碳基柱体，然后将碳基柱体升温至造孔剂的气化温度，保温10～20h，再升温至100～150℃，保温100～250h，然后复压得到具有连通管孔隙的受电弓碳滑板坯体。
3.浸渍：
a)将已压制好的受电弓碳滑板坯体置于焙烧炉1的炉腔内，并将铜金属和同时与铜、碳材料相互结合很好的钎料(铁、钛、锆、铬等)混合均匀后置于石墨坩埚3内，石墨坩埚3安装于焙烧炉1中；熔融后的铜-钎料熔融金属4中钎料的质量分数为1％～10％；
b)将焙烧炉1炉膛抽真空至0.1Pa左右，同时抽出炉膛和受电弓碳滑板坯体6内部空隙的气体；抽真空过程如图1所示；
c)将石墨坩埚3中的铜合金和钎料加热至熔融状态，同时将受电弓碳滑板坯体6加热至800～1300℃；
d)旋转旋杆5，将石墨坩3中的铜合金液倾倒入焙烧炉腔内，在3～14T的磁场条件下往炉膛内通保护气体(氮气、氩气等)至炉内压力为3～8MPa，使得铜合金液逐渐压入坯体空隙，浸渍过程保温保压1～2h；浸渍过程如图2所示；
e)当铜合金液充满碳坯体空隙后，泄压，利用机械臂2从铜合金液中取出受电弓碳滑板坯体6，冷却，完成浸渍过程。
4.烧结：将浸渍后的碳滑板坯体6放置在烧结炉内，隔绝空气进行加热，控制烧结温度为1000～1200℃、烧结时间15～20h，得到滑板半成品；
5.石墨化处理：将滑板半成品放入高温石墨化炉内进行石墨化处理，即将碳滑板半成品置于石墨化炉内的保护介质中加热到2300～2500℃的高温，加热过程中在1200℃以前升温速率为5℃/min，1200℃以后升温速率为30℃/h；然后在2300～2500℃的温度下保温2～4h，六角碳原子平面网格从二维空间的无序重叠转变为三维空间的有序重叠，在碳滑板半成品中形成石墨结构，得到受电弓碳滑板。
在本方案铜-钎料混合溶液浸渍碳滑板的过程中，铜与碳之间将出现过渡层，该过渡层主要用于连接铜与碳材料。如图3所示，在碳-铜界面处，钎料与碳在高温下发生化学反应，生成碳化物，碳化物与钎料和碳材料均有很好的润湿性，使得碳材料与钎料结合更紧密；同时钎料中金属原子与铜原子大小接近，它们的结合力大，使得钎料与铜材料结合更紧密。因此，通过上述钎焊层的过渡，使得原本相互润湿性差的铜与碳材料结合更紧密。
步骤3中的浸渍利用磁场焙烧炉系统完成，其结构如图4所示。磁场焙烧炉系统主要由磁场发生装置、高温烧结炉和温控系统三部分组成；其中，磁场发生装置包括但不限于导电线圈，当为导电线圈10时，在导电线圈10中通入高强度直流电会产生竖直方向的静磁场，其最大的磁感应强度可达到12～18T，磁场均一度在0.02％～0.3％以内，励磁速度为3～16T/30min，高温烧结炉安装在磁体的型腔中，最高加热温度可达1200℃，加热温度由固定在加热炉内的R型热电偶测量，测量精度为+5℃，升温速率为5K/min，金属合金试样放置在高强石墨坩埚中，通过调节其进入炉体内部的深度，控制所需磁场条件，试样分别置于Bmax(磁体中心)处和-B(dB/dz)max(磁体中心向上100mm)处。
本发明中的方法不仅适用于受电弓碳滑板，还应适用于所有电碳材料，如碳刷等。
下面结合实施例对本发明的具体实施方式做详细的说明。
实施例一
一种高电导率受电弓碳滑板的制备方法，包括以下步骤：
1.混捏：取65质量份的沥青焦粉、25质量份的石墨粉和8质量份的高温沥青作为基料；按照重量配比将沥青焦粉和石墨粉放入混捏锅中，并添加占基料总质量5％的甲基纤维素，充分混合1h，所用甲基纤维素的直径为0.2mm、长度为70mm；再加入熔融的高温沥青并混合均匀，冷却后再将混料放入球磨机中进行磨粉处理，得到粒度为250目左右的碳滑板骨料。
2.压制：将碳滑板骨料在200T的液压机中预压为25mm*35mm*1200mm的碳基柱体，然后将碳基柱体升温至80℃左右，保温15h，再升温至120℃，保温200h，然后复压得到具有连通管孔隙的受电弓碳滑板坯体。
3.浸渍：将已压制好的受电弓碳滑板坯体置于焙烧炉中，抽真空至0.1Pa左右，并加热至1000℃左右，在加热受电弓碳滑板坯体的同时加热铜合金和钎料至熔融状态，然后将熔融态的铜合金液倒入焙烧炉中浸没受电弓碳滑板坯，再充入氮气至焙烧炉内压力为5MPa，同时外加8T的磁场，保持2h，完成浸渍；铜合金液中包含质量分数为5％的铁钎料。
4.烧结：将浸渍后的碳滑板坯体放置在烧结炉内，隔绝空气进行加热，控制烧结温度为1100℃、烧结时间18h，得到滑板半成品；
5.石墨化处理：将滑板半成品置于石墨化炉内的保护介质中，然后以5℃/min的加热速率将滑板半成品加热至1200℃，再以30℃/h的加热速率将滑板半成品加热至2400℃，在此温度下保温3h，六角碳原子平面网格从二维空间的无序重叠转变为三维空间的有序重叠，在碳滑板半成品中形成石墨结构，得到受电弓碳滑板。
实施例二
一种高电导率受电弓碳滑板的制备方法，包括以下步骤：
1.混捏：取70质量份的沥青焦粉、20质量份的石墨粉和10质量份的高温沥青作为基料；按照重量配比将两种粒度的沥青焦粉和石墨粉放入混捏锅中，并添加占基料总质量15％的碳酸铵，充分混合1h，所用碳酸铵的直径为0.1mm、长度为50mm；再加入熔融的高温沥青并混合均匀，冷却后再将混料放入球磨机中进行磨粉处理，得到粒度为200目左右的碳滑板骨料。
2.压制：将碳滑板骨料在200T的液压机中预压为25mm*35mm*1200mm的碳基柱体，然后将碳基柱体升温至70℃左右，保温20h，再升温至150℃，保温150h，然后复压得到具有连通管孔隙的受电弓碳滑板坯体。
3.浸渍：将已压制好的受电弓碳滑板坯体置于焙烧炉中，抽真空至0.1Pa左右，并加热至1300℃左右，在加热受电弓碳滑板坯体的同时加热铜合金和钎料至熔融状态，然后将熔融态的铜合金液倒入焙烧炉中浸没受电弓碳滑板坯，再充入氮气至焙烧炉内压力为3MPa，同时外加14T的磁场，保持2h，完成浸渍；铜合金液中包含质量分数为8％的钛钎料。
4.烧结：将浸渍后的碳滑板坯体放置在烧结炉内，隔绝空气进行加热，控制烧结温度为1200℃、烧结时间15h，得到滑板半成品；
5.石墨化处理：将滑板半成品置于石墨化炉内的保护介质中，然后以5℃/min的加热速率将滑板半成品加热至1200℃，再以30℃/h的加热速率将滑板半成品加热至2500℃，在此温度下保温2h，六角碳原子平面网格从二维空间的无序重叠转变为三维空间的有序重叠，在碳滑板半成品中形成石墨结构，得到受电弓碳滑板。
实施例三
一种高电导率受电弓碳滑板的制备方法，包括以下步骤：
1.混捏：取60质量份的沥青焦粉30质量份的石墨粉和5质量份的高温沥青作为基料；按照重量配比将两种粒度的沥青焦粉和石墨粉放入混捏锅中，并添加占基料总质量3％的甲基纤维素，充分混合1h，所用甲基纤维素的直径为0.3mm、长度为100mm；再加入熔融的高温沥青，在160℃的温度条件下混合4h，冷却后再将混料放入球磨机中进行磨粉处理，得到粒度为300目左右的碳滑板骨料。
2.压制：将碳滑板骨料在200T的液压机中预压为25mm*35mm*1200mm的碳基柱体，然后将碳基柱体升温至85℃左右，保温10h，再升温至100℃，保温250h，然后复压得到具有连通管孔隙的受电弓碳滑板坯体。
3.浸渍：将已压制好的受电弓碳滑板坯体置于焙烧炉中，抽真空至0.1Pa左右，并加热至800℃左右，在加热受电弓碳滑板坯体的同时加热铜合金和钎料至熔融状态，然后将熔融态的铜合金液倒入焙烧炉中浸没受电弓碳滑板坯，再充入氮气至焙烧炉内压力为8MPa，同时外加5T的磁场，保持2h，完成浸渍；铜合金液中包含质量分数为6％的锆钎料。
4.烧结：将浸渍后的碳滑板坯体放置在烧结炉内，隔绝空气进行加热，控制烧结温度为1000℃、烧结时间20h，得到滑板半成品；
5.石墨化处理：将滑板半成品置于石墨化炉内的保护介质中，然后以5℃/min的加热速率将滑板半成品加热至1200℃，再以30℃/h的加热速率将滑板半成品加热至2300℃，在此温度下保温4h，六角碳原子平面网格从二维空间的无序重叠转变为三维空间的有序重叠，在碳滑板半成品中形成石墨结构，得到受电弓碳滑板。
虽然结合实施例对本发明的具体实施方式进行了详细地描述，但不应理解为对本专利的保护范围的限定。在权利要求书所描述的范围内，本领域技术人员不经创造性劳动即可作出的各种修改和变形仍属本专利的保护范围。

Claims (10)

1.一种高电导率受电弓碳滑板的制备方法，其特征在于，包括以下步骤：
(1)制备坯体：将包含造孔剂的碳滑板骨料预压为碳基柱体，然后将碳基柱体升温至70～85℃，保温10～20h，再升温至100～150℃，保温100～250h，然后复压得受电弓碳滑板坯体；所述造孔剂为直径为0.1～0.3mm、长度为50～100mm的线型材料；
(2)浸渍：将受电弓碳滑板坯体放入焙烧炉中，抽真空后加热至800～1300℃，同时加热铜合金和钎料至熔融状态，然后将熔融态的铜合金液倒入焙烧炉中浸没受电弓碳滑板坯体，接着充入保护气体至焙烧炉内压力为3～8MPa，同时外加3～14T的磁场，保持1～2h，完成浸渍；所述铜合金液中包括质量分数为1％～10％的钎料；
(3)烧结：在隔绝空气的条件下，用1000～1200℃的温度对浸渍后的碳滑板坯体进行烧结，烧结时间为15～20h，得碳滑板半成品；
(4)石墨化处理：将碳滑板半成品置于石墨化炉内，并加热至2300～2500℃，保温2～4h，得高电导率受电弓碳滑板。
2.根据权利要求1所述的高电导率受电弓碳滑板的制备方法，其特征在于：所述造孔剂占碳滑板骨料总重量的1～15％。
3.根据权利要求2所述的高电导率受电弓碳滑板的制备方法，其特征在于，所述碳滑板骨料的制备方法为：取以下质量份的组分：沥青焦粉60～70份，石墨粉20～30份，高温沥青5～10份以及上述三种原料总质量1～15％的造孔剂；然后将沥青焦粉、石墨粉和造孔剂均匀混合，再加入熔融的高温沥青，于160～200℃下混合2～4h，然后冷却至室温并将混合料磨成200～300目的粉末，得碳滑板骨料。
4.根据权利要求1～3任一项所述的高电导率受电弓碳滑板的制备方法，其特征在于：所述造孔剂为甲基纤维素或碳酸铵。
5.根据权利要求1所述的高电导率受电弓碳滑板的制备方法，其特征在于：步骤(2)中抽真空后的焙烧炉的真空度为0.05～0.2Pa。
6.根据权利要求1所述的高电导率受电弓碳滑板的制备方法，其特征在于：所述钎料为铁、钛、锆或铬，其在铜合金液中的质量分数为5～8％。
7.根据权利要求1所述的高电导率受电弓碳滑板的制备方法，其特征在于：所述保护气体为氮气或氩气。
8.根据权利要求1所述的高电导率受电弓碳滑板的制备方法，其特征在于：浸渍过程中焙烧炉内压力为5MPa，外加磁场强度为8T。
9.根据权利要求1所述的高电导率受电弓碳滑板的制备方法，其特征在于：步骤(4)中加热分两段进行，在碳滑板半成品温度达到1200℃以前，升温速率为5℃/min，超过1200℃以后，升温速率为30℃/h。
10.采用权利要求1～9任一项所述制备方法所制备的受电弓碳滑板。
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